IMS Replacement... The Jager Saga

[Jager]

986 Forum team,
I’m not sure how many pictures I can add in a single post, or how many pictures can be put on a thread, most likely I will find out the hard way. If you’re like me I really enjoy looking at the pictures from others on this site. I would like to share my project with the forum; hopefully a few folks will cheer me on while others will give me a hard time, and yet I know others will help if I run into problems. Brucelee please don’t get too upset if I use-up all the hard drive space on the server. : 0

A post from a well know member of this forum a few weeks ago, in response to a question I had on, “what’s the highest mileage you have seen on a Boxster?” (BTW I have over 210,000 miles on my car now) got me out of my chair to dust-off the old torque wrenches. My 2001 Boxster has been a great car, the best car I have ever owned, but I was reminded, indirectly, that I should take care of a known possible issue, and not to ignore its faithful wearing of parts.

While digging deep into the guts of my 986 I will replace the flywheel, clutch, rear main seal, O2 sensors, and motor mount.

[Jager]

I like these eye protectors.

[Jager]

I put grease under the tool nut (nut box end wrench is on) and turned the box end wrench keeping the end of tool (ratchet end) from turning.

[Jager]

Uncovered the motor...

[Jager]

Out came the old bearing, it was very easy to remove.

[Jager]

Drained the oil and replaced plug with LN Engineering (Bigfoot) magnetic plug. Notice the socket size difference between new LN Engineering plug (on the left) and the original plug, 10mm versus 8mm.

[Jager]

A little movement of the bolt, unlike the new bearing that has no movement at all. Also spinning the bearing was stiff… Not as smooth as the new LN Engineering bearing.

[Jager]

Dropped the pan and found about 10 pounds of dirt and gravel. I had to use a shovel to find the top surface of the pan.

[Jager]

This is a cool picture focused down the IMS, looks like the bearing was getting oil… Good sign.

[Jager]

30 minutes later after using wheel cleaner and a brush.

[Jager]

Per LN Engineering instructions put into the freezer. When cold, install.
I took measurements during the freezer time:
Initial diameter: 47.00 mm or 1.8500 inches
After 1 hour: 46.99 mm or 1.8495 inches
After 2 hours: 46.97 or 1.8490 inches
After 3 hours: 46.97 or 1.8490 inches

Looks like two hours in the freezer at 0 degrees Fahrenheit is enough time.

[Jager]

Might replace this someday, but not on this project.

[Jager]

In with the new IMS bearing. Installing the bearing is not easy; you don’t want to be laying on your back or stomach while trying to install the bearing. The car needs to be high enough so you can at least sit or stand while doing this task. No beer drinking during this task!! I had a heck of a time lining-up the bearing with the IMS shaft (no I was not drinking beer). The trick was to wiggle it back and forth, while trying to insert it, and feel it slip-in the shaft a little before hitting the insert tool with a “dead blow” hammer.

[Jager]

Transmission is next

[Jager]

Last task for the day was the installation of the flywheel... Sure looks good. I marked the bolts with black marker after first step torque to 25 Newton Meters and then turning another 120 degrees.

[tawheed]

Awesome thread and pics!! I was going to attempt this in my garage as well, great work! Must be a huge sense of accomplishment

[Jager]

I don’t think I have ever done a double take while working under a car but WTF is this? I don’t have that tool! A 10mm triple square near the bottom of the transmission on the driver’s side.. I did not catch this in the instructions. Dang it, now I had to find this socket.

Not a single store in town had triple square bits/sockets. So I called Snap On to see if he was coming my way today… Yes!

Now that I have a full set of triple square sockets/bits I was ready to hit it again.

[Jager]

Transmission is down, clutch and flywheel removed. Almost down to the rivets on the clutch plate.

[nnewell]

Great thread, any idea if the old clutch was the original?

Thanks,
~ Nick

[Jager]

Originally Posted by nnewell

Great thread, any idea if the old clutch was the original?

Thanks,
~ Nick

It was not the original clutch, but the flywheel was original.

Jager